I have a stuck 4wd axle disconnect stuck in pan what I was wondering if I bought a new disconnect could I split the new one and put the new front housing on to the old housing afraid I'm going to break housing in oil pan .
Do you no if they have a rebuild kit for the front housingYou could possibly do that. Couldn't replace the inner seal doing it that way, but, if that seal is OK you may be fine to get away with it.
If your outer housing is in good shape still, you may be able to take it apart and rebuild the whole thing on the side of the vehicle. I haven't tried, I broke mine trying to get it off.
If it breaks, try (carefully!) drilling holes in the broken chunk but don't drill into the oil pan itself, and use a cold chisel to break it up.